Method and apparatus for compression of ammonia synthesis gas and recycle gas for the production of ammonia by screw compressors

ABSTRACT

A method for producing ammonia may be provided. The method may include supplying ammonia synthesis gas to a synthesis gas screw compressor and compressing the synthesis gas. The compressed synthesis gas may be joined with a flow of recycle gas compressed in a recycle gas screw compressor. The compressed combined flow may then be introduced to an ammonia reactor. The ammonia reactor may discharge ammonia, purge gas, and unconverted gas, which may be the recycle gas.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority as a Continuation application of U.S.patent application Ser. No. 15/832,220, filed on Dec. 5, 2017, which isa Continuation-In-Part application of U.S. patent application Ser. No.14/987,779, filed on Jan. 5, 2016, the contents of which are herebyincorporated by reference in their entireties.

BACKGROUND

The discovery of Haber and developments by Bosch of the reactionN2+3H2=2NH3 to produce ammonia was in relation to the World anepoch-making discovery and led to ammonia being one of the top tonnagechemicals in World production.

There is no doubt that without this discovery the burgeoning worldpopulation would have been subject to increased starvation.

The first commercial production of 20 metric tons of ammonia per day wasby BASF in 1913. This enabled the Germans to produce nitrate explosiveswithout the import of Chilean Saltpetre an important factor in World WarI.

One of the pioneers in the subsequent development of the ammoniasynthesis was the Italian company Ammonia Casale who have remained aworld leader.

Casale recommended a synthesis pressure of 600 atm so the ammonia ex thereactor could be condensed without a refrigeration compressor. PostWorld War II ammonia plants tended to have a capacity of around 300metric tons/day the limitation being the size of the reciprocatingsynthesis compressors which in general were horizontally opposed units.

In Wyoming for example these plants were considered rather like gasstations serving an agricultural community of around 250-mile radiuscurve from the ammonia production. In 1954 Torresy and Hamilton produceddesigns for skid mounted units of 100 and 200 short tons/day of ammonia.These plants had horizontally opposed reciprocating synthesis gas drivenby synchronous electric motors. Specific consumption in thermallyequivalent gas was 50 MM BTU/metric ton of ammonia. Some 30 of theseplants which were fabricated by Krupp in Germany and Voest in Austriawere sold worldwide and some are still operating including one in Sudanwhich was never started up because the Sudanese government did notsupply the gas. Commercially these plants were a success at the timebecause the buyer had only to provide the civil work for the foundationsand the need for mechanical erection was eliminated.

In the 1960's the M. W. Kellogg Company opened the era of mega-ammoniaplants with a radical new design. This design involved raising steamfrom the primary and secondary reformer to supply steam turbines drivingthe centrifugal synthesis gas, recycle and refrigeration compressors andreducing the ammonia synthesis pressure to between 140 and 160 atm. Gasconsumption was reduced to around 30 MMBTU/metric ton of ammonia withthe plant having minimal electricity consumption. The centrifugalcompressors opened the way to increased flows and consequently higherammonia capacity. The first plant to utilize the process was theMississippi Chemical Corporation with a capacity of 1000 metrictons/day. However, the physical limitations of centrifugal compressorsmeant it was not possible to design ammonia plants with a capacity of orbelow 500 metric tons/day.

For this development M. W. Kellogg received the prestigious 1967Kirkpatrick Chemical Engineering Award. In Van Nostrand's ScientificEncyclopedia Eighth Edition a Reference 1 this is described and thefollowing statements made

“Most ammonia plants built since early 1960s in the 600-1500 short tonsof ammonia per day are based on the new integrated process”

“One of the major factors contributing to the improved economics ofammonia plant is the application of multistage centrifugal compressorswhich have replaced reciprocating compressors traditionally used in thesynthesis feed and recycle service by a single centrifugal compressor”

“Developments have been centered around the 1960s basic process schemewith modifications to improve efficiency therefore the basic processsteps have not changed in any major way”

The first statement of a lower limit of 600 short tons a day of ammoniawas because this was the lower limit of the recycle wheel in thecentrifugal compressor in this process design.

Until today ammonia plants of this lower capacity have usedreciprocating compressors for the synthesis and recycle duty.Reciprocating compressors are expensive and require frequentmaintenance.

The cost of ammonia production is largely based on two factors, theprice of gas and the capital charges.

New ammonia plants producing 2000 metric tons of ammonia per day with anaccompanying urea plant can cost around 1 billion and face majorproblems in implementation. Financiers cannot often obtain adequateinformation on the security of the market. The plants are oftenprojected in areas where the field construction is difficult and thecost uncertain. Buyers normally want turnkey plants. This compels thecontractor to include high levels of profit and contingency to cover therisk.

This all points to the need to develop small economic ammonia plantswhich can be situated in countries where the fertilizer consumption perunit area is low and also in countries where cheap fracked gas isavailable such as the United States.

Small ammonia plants will not succeed unless their gas consumption permetric ton of ammonia is equivalent to that of a major scale plant andfurther their capital cost is pro-rata to that of the larger plant.

It therefore may be desired for a process method of removing thisbottleneck and lowering the cost of ammonia plants. Two recentimprovements have contributed to this ability. Improved ammoniasynthesis catalysts lead to the ability to synthesize ammonia at apressure between 70-120 bar. Concurrently in 2009 KOBELCO, Japandeveloped the first screw compressors capable of a delivery pressure of100 bar. Previously screw compressors which were widely used had amaximum delivery pressure of 66 bar.

SUMMARY

A method for producing ammonia may be provided. The method may includesupplying ammonia synthesis gas to a synthesis gas screw compressor andcompressing the synthesis gas. The compressed synthesis gas may bejoined with a flow of compressed recycle gas The compressed combinedflow may then be introduced to an ammonia reactor. The ammonia reactormay discharge ammonia, purge gas, and unconverted gas, which may be therecycle gas. The recycle gas may be compressed in a recycle gascompressor and supplied to the flow of compressed ammonia synthesis gas.

According to another exemplary embodiment, a method for producingammonia may be provided. The method may include supplying ammoniasynthesis gas to a screw compressor. A flow of recycle gas may also beintroduced to the screw compressor. The ammonia synthesis gas andrecycle gas may be compressed in the screw compressor. A flow ofcompressed ammonia synthesis gas and recycle gas may be discharged as acombined gas flow. The compressed combined gas flow may be supplied toan ammonia reactor. The ammonia reactor may discharge ammonia, purgegas, and recycle gas. The recycle gas may be supplied to the screwcompressor.

According to yet another exemplary embodiment, an apparatus forproducing ammonia may be provided. The apparatus for producing ammoniamay include an ammonia reactor configured to receive compressed ammoniasynthesis gas and compressed recycle gas and discharge ammonia product,purge gas, and recycle gas. The apparatus may further include asynthesis gas screw compressor configured to compress a flow of ammoniasynthesis gas and supply the flow of compressed ammonia synthesis gas tothe ammonia reactor. The apparatus may also include a recycle gas screwcompressor configured to receive recycle gas from the ammonia reactor,compress the recycle gas, and reintroduce the recycle gas to the ammoniareactor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exemplary block flow chart configuration for thecompression of ammonia synthesis gas and recycle gas for the productionof ammonia by screw compressors.

FIG. 2 shows another exemplary block flow chart configuration for thecompression of ammonia synthesis gas and recycle gas for the productionof ammonia by screw compressors.

FIG. 3 shows another exemplary block flow chart configuration for thecompression of ammonia synthesis gas and recycle gas for the productionof ammonia by screw compressors.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the invention are disclosed in the following description andrelated drawings directed to specific embodiments of the invention.Alternate embodiments may be devised without departing from the spiritor the scope of the invention. Additionally, well-known elements ofexemplary embodiments of the invention will not be described in detailor will be omitted so as not to obscure the relevant details of theinvention. Further, to facilitate an understanding of the descriptiondiscussion of several terms used herein follows.

As used herein, the word “exemplary” means “serving as an example,instance or illustration.” The embodiments described herein are notlimiting, but rather are exemplary only. It should be understood thatthe described embodiments are not necessarily to be construed aspreferred or advantageous over other embodiments. Moreover, the terms“embodiments of the invention”, “embodiments” or “invention” do notrequire that all embodiments of the invention include the discussedfeature, advantage or mode of operation.

According to the present invention, the use of screw compressorscompressing to 120 bar may be utilized, which has never been used forthe compression of synthesis gas and the recycle gas. This enables theutilization of the waste heat from the synthesis gas plant and with aconventional methane reformer system leads to a gas consumption of 30MMBTU/metric ton of ammonia. With improved designs in the reformersection, the utilization of the screw compressors as detailed herein,and low cost skid assembly, the capital cost can be matched pro-rata toa larger plant.

According to an exemplary embodiment, a method may be provided forcompressing pure ammonia synthesis gas N2+3H2, or with limited contentof methane and inert gases and recycle gas, by a screw compressor. Thesynthesis gas screw compressor compressing ammonia synthesis gas with apressure of between 20 bar and 50 bar, with a volume limited to 60,000standard cubic meters per hour up to 120 bar discharge pressure,according to the block flow drawing.

Now referring to exemplary FIG. 1, ammonia synthesis gas 102, N2+3H2,may be supplied to a synthesis gas screw compressor 110. The synthesisgas 102 (syngas) may have the stoichiometric volumes of nitrogen andhydrogen for ammonia synthesis and may have small amounts of impuritiessuch as inert gases and methane. In some exemplary embodiments, thesyngas may be in the near molar proportions of 1:3. The ammoniasynthesis gas 102 may be supplied with an inlet pressure of 20 bar to 50bar, depending on the synthesis gas process adopted. The synthesis gasscrew compressor 110 may compress the ammonia synthesis gas 102 anddischarge compressed ammonia synthesis gas 104. The synthesis gas screwcompressor 110 may discharge the compressed ammonia synthesis gas 104with a pressure of 70 bar to 120 bar. According to some exemplaryembodiments, the synthesis gas screw compressor 110 may be a singlestage oil-flooded screw gas compressor driven by an electric motor orsteam turbine.

Upon discharge from the synthesis gas screw compressor 110, thecompressed ammonia synthesis gas 104 may be joined by recycle gas 122from a recycle screw compressor 120 forming gas flow 108. The recyclegas 122 may have a pressure of 76 bar to 116 bar. The combined gas flow108 may flow to an ammonia synthesis reactor 130, which may operate at apressure of 70 bar to 120 bar. Partial conversion of the combined gasflow 108 to ammonia may occur. Unconverted gas portions 132 may pass tothe recycle screw compressor 120. The unconverted gas portions 132 mayhave a pressure of 66 bar to 116 bar when passed to the recycle screwcompressor 120. The recycle screw compressor 120 may compress theunconverted gas 132 and introduce compressed unconverted recycle gas 122to the compressed ammonia synthesis gas flow 104 from the synthesis gasscrew compressor 110 before returning to the ammonia synthesis reactor130. The recycle screw compressor 120 may be driven by an electric motoror steam turbine and may compress the recycle gas to a pressure of76-116 bar, as noted above, for blending with the already compressedsyngas. The ammonia synthesis reactor 130 may also discharge ammoniaproduct 134 and purge-gas (not shown), which may be separated to recoverhydrogen or which may be sent for fuel use. The ammonia product 134 maybe sent to the user or to ammonia storage.

In some embodiments, the ammonia synthesis reactor 130 may be aconventional single or multi-pass converter using one or more magnetitecatalyst or using one or more noble metal catalyst based on ruthenium,U.S. Pat. No. 9,150,423 to Hosono et al. The ammonia synthesis reactor130 may further include a waste heat boiler and an ammonia condenserhaving any mechanical or chemical system capable of more selectivelyseparating ammonia from a gas mixture including at least hydrogen andnitrogen, as would be understood by a person having ordinary skill inthe art. The ammonia condenser may include one or more cryogenicpurifiers, including one or more refrigeration exchangers and one ormore refrigeration compressors. U.S. Pat. No. 8,926,909 to Filippi etal. describes a method for modernizing the ammonia synthesis loop.

The above referenced screw compressors may be in one of threeconfigurations, as single units, both units on one driver shaft, or asone unit combining both functions. The method may further lead to theutilization of spare heat from a conventional steam reformer and partialoxidation synthesis gas preparation units, which may provide high energyefficiency and low capital cost.

Now referring to exemplary FIG. 2, a system utilizing a synthesis gascompressor and recycle gas compressor in series may be disclosed. Insome embodiments, the screw compressors may be disposed on a singledrive shaft. As in the system and process shown in FIG. 1, syngas 202may be provided to a syngas compressor 210. Recycle gas 232 may besupplied to a recycle gas compressor 220 on the same drive shaft assyngas compressor 210, where recycle gas 232 may be compressed. Thecompressed syngas 204 may bypass the recycle gas compressor 220 and beintroduced and combined with the compressed recycle gas 222 formingcompressed gas flow 208, which may be introduced to an ammonia synthesisreactor 230. The synthesis gas compressor 210 and the recycle gascompressor 220 may be disposed on a single driver shaft which may bedriven by one electric motor or steam turbine. The ammonia synthesisreactor 230 may in turn discharge ammonia product 234, purge or off gas(not shown) and recycle gas 232, as described above.

In still further exemplary embodiments, as shown in FIG. 3, thesynthesis gas 302 and recycle gas 332 may be combined and compressed ina single synthesis and recycle gas compressor 310. The synthesis andrecycle gas compressor 310 may be in one casing and may be driven by oneelectric motor or steam turbine. The synthesis gas 302 and recycle gas332 may enter the compressor 310 independently and be combined incompressor 310. According to some embodiments, the recycle gas andsynthesis gas may be introduced to the compressor at different stages ofcompression, based on their prior differences in pressure. For example,the recycle gas may be introduced into the compressor at a later stageof compression.

The foregoing description and accompanying figures illustrate theprinciples, preferred embodiments and modes of operation of theinvention. However, the invention should not be construed as beinglimited to the particular embodiments discussed above. Additionalvariations of the embodiments discussed above will be appreciated bythose skilled in the art (for example, features associated with certainconfigurations of the invention may instead be associated with any otherconfigurations of the invention, as desired).

Therefore, the above-described embodiments should be regarded asillustrative rather than restrictive. Accordingly, it should beappreciated that variations to those embodiments can be made by thoseskilled in the art without departing from the scope of the invention asdefined by the following claims.

What is claimed is:
 1. A system for producing ammonia comprising: atleast one screw compressor; and an ammonia reactor, wherein the at leastone screw compressor compresses at least one of ammonia synthesis gasand recycle gas and supplies a compressed gas flow to the ammoniareactor, and wherein the ammonia reactor discharges produced ammonia,purge gas, and recycle gas.
 2. The system of claim 1, comprising onescrew compressor configured to receive and compress ammonia synthesisgas and recycle gas, and supply a compressed flow of combined synthesisgas and recycle gas to the ammonia reactor.
 3. The system of claim 1,comprising a first screw compressor configured to receive ammoniasynthesis gas and discharge a flow of compressed ammonia synthesis gasand a second screw compressor configured to receive recycle gas anddischarge a flow of compressed recycle gas, wherein the flows ofcompressed synthesis gas and compressed recycle gas are combined andsupplied to the ammonia reactor.
 4. The system of claim 3, wherein thefirst screw compressor and the second screw compressor are disposed on asingle shaft.
 5. The system of claim 3, wherein the first screwcompressor and the second screw compressor are disposed on separateshafts.
 6. The of claim 1, wherein the ammonia reactor is configured tosupply the recycle gas to the at least one screw compressor.
 7. A methodfor producing ammonia comprising: supplying ammonia synthesis gas to ascrew compressor; compressing the ammonia synthesis gas in the screwcompressor; discharging a flow of compressed ammonia synthesis gas;combining a flow of compressed recycle gas with the flow of compressedammonia synthesis gas, forming a compressed combined gas flow; supplyingthe compressed combined gas flow to an ammonia reactor, wherein theammonia reactor discharges a produced ammonia, purge gas, and recyclegas; supplying the recycle gas to a screw compressor; compressing therecycle gas; and supplying the compressed recycle gas to the flow ofcompressed ammonia synthesis gas.
 8. The method of claim 7, wherein thesynthesis gas and recycle gas are compressed in a single screwcompressor.
 9. The method of claim 7, further comprising a first screwcompressor and a second screw compressor, wherein the synthesis gas iscompressed in a first screw compressor and the recycle gas is compressedin a second screw compressor.
 10. The method of claim 9, wherein thesynthesis gas screw compressor and recycle gas screw compressor aredisposed on a single shaft.
 11. The method of claim 9, wherein thesynthesis gas screw compressor and recycle gas screw compressor aredisposed on separate shafts.